Clip lock visor

ABSTRACT

A sun visor, which generally includes a foundation which maybe folded unto itself to form two foundation halves, and an upholstery cover disposed over the foundation, the foundation halves include connecting elements which engage one another to secure the foundation halves together. Additionally, a frame member may be disposed between the folded foundation halves, the frame member including connecting elements which engage corresponding connecting elements of the foundation halves to secure the foundation halves to the frame member. For example, in one embodiment, a plurality of clips may be integrally formed in a pair of connecting strips which are each associated with a foundation half, the clips of the connecting strips engaging one another when the foundation halves are pressed together to secure the foundation halves together.

RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.09/788,241, filed on Feb. 16, 2001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to sun visors for vehicles, thesun visors of the type which include an outer covering which folds untoitself. In particular, the present invention relates to the manner inwhich the folded halves of such outer coverings are attached to oneanother during assembly of the sun visor.

2. Description of the Related Art

A prior sun visor design is disclosed in U.S. patent application Ser.No. 6,527,328, issued on Mar. 4, 2003, assigned to the assignee of thepresent application, the disclosure of which is hereby incorporated byreference. The sun visor disclosed in the '328 patent generally includesan outer upholstery cover and a foundation, in which the foundationfolds unto itself and is covered by the outer upholstery cover. A pairof bead member sections, each having a bulbous bead portion therearoundwhich corresponds to the edge of the sun visor, are attached to thefoundation, and edges of the upholstery cover are tucked into theinterior of the sun visor and secured thereto with adhesive. Finally,adhesive is applied around the interior edges of the foundation, and thefoundation is folded unto itself to define two foundation halves whichare secured to one another by the adhesive to complete the assembly ofthe sun visor, with the bulbous head portions of the bead membersections together defining a rounded edge around the periphery of thesun visor.

The foregoing sun visor may be manufactured using an automated processincluding several individual assembly steps. In one such step, the beadmember sections are attached to the foundation such that stakesprojecting from the bead member sections protrude through receivingholes in the foundation. The stakes are then heat fused, such that theheads of the stakes deform and flatten to secure the bead membersections to the foundation. The upholstery cover is then attached to thefoundation such that peripheral edges of the upholstery cover foldaround the edges of the foundation and are secured to the foundation byadhesive.

Next, the sun visor is securely held in a predefined, exact position bya clamping apparatus as an automatic adhesive application head follows apredetermined, computer-controlled path to apply a beading of liquidadhesive around the edges of the foundation. Thereafter, the foundationis folded unto itself in a folding jig which subsequently holds thefoundation halves together under pressure for a predetermined amount oftime to allow the adhesive to set to complete the assembly of the sunvisor.

Although the above-described sun visor design has proven successful,manufacturing the sun visor requires many individual assembly steps, asdescribed above, with each step requiring expensive and complexmachinery. The adhesive itself, which is used to secure the sun visorcomponents together, is also rather expensive. In addition, thedifficulty of re-tooling the automated process to manufacture differentvisor designs increases with the complexity and number of automatedassembly steps.

What is needed it a sun visor which is both easier and less expensive tomanufacture than the above-described sun visor, yet which provides asecure and durable connection between the foundation halves of the sunvisor.

SUMMARY OF THE INVENTION

The present invention provides a sun visor, the sun visor generallyincluding a foundation which may be folded unto itself to form twofoundation halves, and an upholstery cover disposed over the foundation,where the foundation halves include connecting elements which engage oneanother to secure the foundation halves together. A frame member may bedisposed between the folded foundation halves, the frame memberincluding connecting elements which engage corresponding connectingelements of the foundation halves to secure the foundation halves to theframe member.

The connecting elements may be, for example, a plurality of clipsassociated with each foundation half, such that when the foundationhalves are pressed together, corresponding clips engage one another tosecure the foundation halves together with a snap lock connection. Theclips may be disposed and retained within apertures in the foundationhalves. Optionally, the foundation halves may include recesses in theexternal surfaces thereof around each aperture, the recesses receivingthe heads of the clips such that the external surfaces of the foundationhalves are substantially flush with the heads of the clips to allow theupholstery cover to uniformly cover the foundation halves and hide theclips from view.

The connecting elements may include a pair of connecting strips whichare respectively associated with the foundation halves and include aplurality of clips formed therewith, with the clips of the pair ofconnecting strips engaging one another when the foundation halves arepressed together to secure the foundation halves together. Rather thanclips, the connecting strips may optionally include a plurality ofengaging rachet legs, or a plurality of posts formed with one connectingstrip which engage a corresponding plurality of locking fingers ofanother connecting strip.

Additionally, a frame member may be disposed between the foundationhalves, the frame member including a plurality of apertures thereinthrough which the clips extend to engage one another to secure thefoundation halves together, with the frame member sandwiched between thefoundation halves. Alternatively, the frame member may include aplurality of clip receptacles alternatingly disposed in opposite sidesthereof, with the clips of the foundation halves engaging the clipreceptacles to secure the foundation halves to the frame member. Theframe member may optionally include a rounded beading disposedexternally of the foundation halves and the upholstery cover, therounded beading forming an edge portion of the sun visor.

In addition to interlocking clips, the present invention providesinterlocking systems to secure the foundation halves of the sun visortogether. For example, the sun visor may include a frame member having aplurality of slots on opposite sides of the frame member, the foundationhalves including a plurality of integrally formed tabs which arereceived within the slots of the frame member to lock the foundationhalves to opposite sides of frame member. Alternatively, the framemember may include a plurality of T-shaped tabs extending from oppositesides thereof, and the foundation halves may include a plurality ofrecessed cavities formed therein which include slots, the T-shaped tabsslidingly received within the slots to secure the foundation halves toopposite sides of the frame member.

Additionally, adhesive strips may be used to secure the foundationhalves of the sun visor together, the adhesive strips having exposedadhesive on opposite sides thereof. The adhesive strips may besandwiched between the foundation halves to directly secure thefoundation halves together, or may be sandwiched between each foundationhalf and a frame member to secure the foundation halves to the framemember.

Advantageously, the various interlocking connections between thefoundation halves, or between the foundation halves and the framemember, obviate the use of expensive adhesive to secure the foundationhalves together, thereby reducing the cost and difficulty ofmanufacturing the sun visor. Also, the interlocking foundation halves ofthe sun visor may be secured to one another in a single step, therebyeliminating several of the above-described assembly steps associatedwith heat staking, adhesive application, and holding the foldedfoundation halves together under pressure to allow the adhesive to cure.The sun visor of the present invention may therefore be assembled usingan automated manufacturing process which is less complex and expensivethan the prior process.

Similarly, the adhesive strips also reduce the cost and difficulty ofmanufacturing the sun visor by obviating the use of a liquid adhesivewhich must be mechanically applied, after which the sun visor is heldunder pressure for the adhesive to set.

In one form thereof, a sun visor is provided, including a substantiallyflat foundation folded unto itself to form two foundation halves, thehalves having corresponding shapes that define an edge of the sun visor;a cover disposed over the foundation and forming an exterior surface ofthe sun visor; and at least one connecting element associated with eachfoundation half, corresponding connecting elements of the two foundationhalves engaging one another to secure the foundation halves together.

In another form thereof, a sun visor is provided, including asubstantially flat foundation folded unto itself to form two foundationhalves, the halves having corresponding shapes that define an edge ofthe sun visor; a cover disposed over the foundation and forming anexterior surface of the sun visor; a frame member disposed intermediatethe foundation halves, the frame member including a rounded bead memberdisposed along the edge of said sun visor externally of the foundationand the upholstery cover; at least one first connecting elementassociated with each foundation half, and at least two second connectingelements associated with the frame member, the first connecting elementsrespectively engaging the second connecting elements to secure thefoundation halves to the frame member.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention,and the manner of attaining them, will become more apparent and theinvention itself will be better understood by reference to the followingdescription of embodiments of the invention taken in conjunction withthe accompanying drawings, wherein:

FIG. 1 is an exploded perspective view of a prior sun visor assembly,including the foundation, upholstery cover, and bead member sections;

FIG. 2 is a perspective view of the sun visor assembly of FIG. 1, shownwith only part of the upholstery cover folded over the edge of thefoundation to illustrate the heat stake attachment of the bead membersections to the foundation, wherein only some of the stakes are fused tothe foundation;

FIG. 3 is a fragmentary sectional view showing a bead member sectionassociated with the foundation prior to heat stake fusion;

FIG. 4 is a fragmentary sectional view showing a bead member sectionsecured to the foundation after heat stake fusion;

FIG. 5 is a fragmentary sectional view of the assembled sun visorassembly of FIGS. 1 and 2;

FIG. 6 is a perspective view of connecting elements, shown as a pair offirst clips, being pressed together into engagement;

FIG. 7 is a fragmentary exploded view of a sun visor assembly of thepresent invention, showing the clips of FIG. 6, the foundation halves,and the upholstery cover;

FIG. 8 is a fragmentary sectional view of the assembled sun visorassembly of FIG. 7;

FIG. 9 is a perspective view of connecting elements, shown as a pair ofsecond clips, being pressed together into engagement;

FIG. 10 is a fragmentary exploded view of an another sun visor assemblyof the present invention, showing the clips of FIG. 9, the foundationhalves, and the upholstery cover;

FIG. 11 is a fragmentary sectional view of the assembled sun visorassembly of FIG. 10;

FIG. 12 is a fragmentary exploded view of an another sun visor assemblyof the present invention, showing a frame member disposed between thefoundation halves, and a pair of clips securing the foundation halvestogether with the frame member therebetween;

FIG. 13 is a fragmentary sectional view of the assembled sun visorassembly of FIG. 12;

FIG. 14 is a perspective view of connecting elements, shown as a pair ofthird clips, being pressed together into engagement;

FIG. 15 is a fragmentary exploded view of an another sun visor assemblyof the present invention, showing the clips of FIG. 14, the foundationhalves, and the upholstery cover;

FIG. 16 is a fragmentary sectional view of the assembled sun visorassembly of FIG. 15;

FIG. 17 is a fragmentary exploded view of an another sun visor assemblyof the present invention, showing a frame member having clip receptaclesand disposed between the foundation halves, and a pair of clips securingthe foundation halves to the frame member;

FIG. 18 is a fragmentary sectional view of the assembled sun visorassembly of FIG. 17;

FIG. 19 is an exploded perspective view of an another sun visor assemblyof the present invention, showing the foundation, the upholstery cover,and a pair of first connecting strips;

FIG. 20 is an perspective view of the sun visor assembly of FIG. 19,showing the first connecting strips associated with the foundation, andalso showing a hinge block for placement between the foundation halves;

FIG. 21 is a sectional view of the assembled sun visor assembly of FIG.20;

FIG. 22a is a fragmentary perspective view of a foundation half ofanother sun visor assembly of the present invention;

FIG. 22b is a fragmentary perspective view of the foundation half ofFIG. 22a, shown with a tab outline and a plurality of recessed notchesformed therein;

FIG. 22c is a fragmentary perspective view of the foundation half ofFIG. 22b, the foundation half including a bent edge portion and adepending tab;

FIG. 23 is a fragmentary exploded view of another sun visor assembly ofthe present invention, including the foundation halves of FIG. 22c, anda frame member disposed between the foundation halves to which thefoundation halves are attached;

FIG. 24a is a sectional view along line 24 a—24 a of FIG. 23;

FIG. 24b is a sectional view along line 24 b—24 b of FIG. 23;

FIG. 25 is a fragmentary view of a pair of foundation halves of afurther sun visor assembly of the present invention, the foundationhalves each including recessed cavities with slots therein;

FIG. 26 is a perspective view of a frame member which may be connectedto the foundation halves of FIG. 25, the frame member including aplurality of T-shaped tabs projecting therefrom;

FIG. 26a is a sectional view along line 26 a—26 a of FIG. 26;

FIG. 26b is a sectional view along line 26 b—26 b of FIG. 26;

FIG. 27 is a fragmentary view of a sun visor assembly including thefoundation halves of FIG. 25 connected to the frame member of FIG. 26;

FIG. 28 is a fragmentary view of a further sun visor assembly of thepresent invention, showing a pair foundation halves which are secured toone another by adhesive strips;

FIG. 29 is a fragmentary view of a further sun visor assembly of thepresent invention, showing a pair foundation halves which are eachsecured to a frame member by adhesive strips;

FIG. 30a is a fragmentary view of a foundation half of a sun visorassembly, shown with a recess around an aperture thereof, and aplurality of segment fingers;

FIG. 30b is a fragmentary view of the foundation half of FIG. 30a, witha clip disposed in the aperture;

FIG. 30c is a fragmentary view of the foundation half and clip of FIG.30b, further showing a portion of an upholstery cover;

FIG. 31a is a fragmentary view of a further sun visor assembly of thepresent invention, showing a pair of second connecting strips associatedwith a pair of foundation halves and an upholstery cover covering thefoundation halves, the foundation halves being pressed together;

FIG. 31b is a fragmentary view of the sun visor assembly of FIG. 31a,with the foundation halves being pressed further together to engage theratchet legs of the second connecting strips;

FIG. 31c is a fragmentary view of the assembled sun visor assembly ofFIGS. 31a-b;

FIG. 32 is a fragmentary view of one of the second connecting strips ofFIGS. 31a-c, showing ratchet legs, hooks, and ribs thereof;

FIG. 33 is a fragmentary sectional view of the assembled sun visorassembly of FIGS. 31c;

FIG. 34a is a fragmentary view of a further sun visor assembly of thepresent invention, showing a pair of third connecting strips associatedwith a pair of foundation halves and an upholstery cover covering thefoundation halves, the foundation halves being pressed together;

FIG. 34b is a fragmentary view of the assembled sun visor assembly ofFIG. 34a; and

FIG. 35 is a fragmentary sectional view of the assembled sun visorassembly of FIG. 34b.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate preferred embodiments of the invention, in several forms, andsuch exemplifications are not to be construed as limiting the scope ofthe invention in any manner.

DETAILED DESCRIPTION

Referring to FIGS. 1-5, a prior sun visor assembly 40 is shown,including a substantially flat foundation 42 which may be folded untoitself to form two foundation halves 44, 46 (shown unfolded in FIGS. 1and 2). Foundation halves 44, 46 have corresponding shapes that, whenfolded together, define edge 48 of sun visor assembly 40, as shown inFIG. 5. Upholstery cover 50 covers foundation 42 and forms an exteriorsurface 52 of visor assembly 40. Visor assembly 40 additionally includesbead member sections 54 having bulbous portions 56 which, when pressedtogether when foundation halves 44, 46 are secured to one another asshown in FIG. 5, form bead member 58 which partially defines edge 48 ofthe sun visor. Bead member sections 54 additionally include stems 60having a plurality of stakes 62 extending therefrom, which fit throughcorresponding apertures 64 formed in foundation 42. FIG. 3 illustrates astake 62 prior to heat stake fusion, with stake 62 extending throughaperture 64 in foundation 42. Stakes 62 are formed of a plasticmaterial, such as polypropylene or ABS plastic, which melts and deformsduring heat staking, as shown in FIG. 4, forming cap 66 that locks stem60 of bead member section 54 against foundation 42 to secure bead membersection 54 to foundation 42.

After stakes 62 have been fused to secure bead member sections 54 tofoundation 42, foundation 42 is placed upon upholstery cover 50, andedge portions 70 of upholstery cover 50 are wrapped around the edges offoundation 42 and attached to the interior periphery of foundation 42using an adhesive. A beading of adhesive 72 is then applied around theinterior edge of foundation 42, and foundation 42 is folded unto itselfto form two foundation halves 44, 46 secured to one another by adhesive72, as described above.

Exemplary embodiments of sun visors of the present invention are shownin FIGS. 6-35, which sun visors include connecting elements for securingthe foundation halves of the sun visor to one another, or alternatively,include a frame member which is disposed between the foundation halvesand which includes connecting elements for securing the foundation halveto the frame member.

One embodiment, visor assembly 74 a, is shown in FIGS. 7 and 8, andincludes upholstery cover 50 and foundation 42, similar to prior visorassembly 40 shown in FIGS. 1-5. Foundation 42 may be made from anysuitable material which is moderately stiff, yet which may be foldedunto itself to form foundation halves 44, 46, such as kraft paper.Upholstery cover 50 may be made from suitable upholstery materials suchas fabric, vinyl, or cloth with bonded foam backing, for example. Visorassembly 74 a also includes a plurality of connecting elementsassociated therewith, the connecting elements shown as clips 78 a whichare received within clip apertures 80 of foundation halves 44, 46.

Referring to FIG. 6, clips 78 a each include head 86 a with a pair ofparallel legs 88 a depending therefrom. Legs 88 a each include at leasttwo pointed parallel arms 90 depending laterally from opposite sides ofeach leg 88 a. Clips 78 a may be pressed together as shown in FIG. 6such that legs 88 a engage one another, with clips 78 a disposed at a90° angle with respect to one another. Each leg 88 a of one clip extendsbetween a pair of legs 88 a of the opposite clip 78 a with arms 90 ofclips 78 a interlockingly engaging one another. Clips 78 a are made of aresilient plastic material which allows legs 88 a and arms 90 toresiliently bend and/or deform as needed, allowing clips 78 a to engageone another with a snap lock connection.

If corresponding clips 78 a are not initially disposed at a 90° anglewith respect to one another, the engagement between arms 90 of opposingclips 78 a automatically rotates clips 78 a with respect to one anotheruntil clips 78 a are disposed at a 90° angle with respect to oneanother, as shown by arrow 79 in FIG. 6. Therefore, corresponding clips78 a associated with foundation halves 44, 46 do not have to be alignedexactly at a 90° angle with respect to one another before foundationhalves 44, 46 are pressed together to engage clips 78 a, whichsimplifies the manufacture of sun visor assembly 74 a.

Visor assembly 74 b, similar to visor assembly 74 a, is shown in FIGS.10 and 11, including clips 78 b which engage one another to securefoundation halves 44, 46 together as described above. Clips 78 b, as maybe seen in FIG. 9, include heads 86 b with a pair of parallel legs 88 bdepending therefrom, each leg 88 b including a row of internallydirected catches 92. Each catch 92 includes a tapered lower side 94 anda top surface 96 which is substantially flat. Legs 88 b also includeintegral support ribs 98 which bisect catches 92.

As shown in FIG. 9, clips 78 b may be pressed together with clips 78 bdisposed at a 90° angle with respect to one another, wherein taperedlower sides 94 of catches 92 of one clip 78 b engage tapered lower sides94 of catches 92 of an opposite clip 78 b to bend legs 88 b of clips 78b slightly outwardly until corresponding catches 92 pass one another,whereupon legs 88 b return to their original positions with top surfaces96 of corresponding catches 92 contacting one another to lock clips 78 btogether. This process is sequentially repeated as clips 78 b arepressed further toward one another, such that catches 92 sequentiallyengage one another in a ratcheting, stepwise manner. Advantageously,this manner of engagement allows the same clips 78 b to be used withfoundations 42 of different thicknesses such that, for example, when arelatively thin foundation is used, three or four catches 92 ofcorresponding clips 78 b may engage one another, and when a relativelythicker foundation is used, one or two catches 92 of corresponding clips78 b may engage one another.

Similar to clips 78 a, and as shown by arrow 79 in FIG. 9, ifcorresponding clips 78 b are not initially disposed at a 90° angle withrespect to one another, contact between tapered lower sides 94 ofcatches 92 automatically rotates clips 78 b with respect to one anotheruntil clips 78 b are disposed at a 90° angle with respect to oneanother, whereupon catches 92 of clips 78 b may properly sequentiallyengage one another as described above.

Sun visor assembly 74 c, similar to sun visor assemblies 74 a and 74 b,is shown in FIGS. 15 and 16, including clips 78 c which engage oneanother to secure foundation halves 44, 46 together as described above.As shown in FIG. 14, each clip 78 c includes head 86 c, and a pair ofparallel legs 88 c depending from head 86 c. Each leg 88 c includes acurved ramp surface 100 on one side thereof, and a hook 102 projectingfrom a sloped distal end 101 of each leg 88 c on a side thereof oppositecurved ramp surface 100. When associated clips 78 c are pressedtogether, each leg 78 c of one clip 78 c extends between legs 88 c ofanother clip 78 c, with hooks 102 contacting opposing curved rampedsurfaces 100, causing clips 78 c to rotate 90° with respect to oneanother before hooks 102 of each leg 88 c are snap-fit into the recessedareas 104 defined between lower edges 106 of curved ramp surfaces 100and the undersides of each hook 102.

Similar to clips 78 a and 78 b, and as shown by arrow 79 in FIG. 14, ifcorresponding clips 78 c are not initially disposed with respect to oneanother as shown in FIG. 14, contact between sloped distal ends 101 ofopposing clips 78 c automatically rotates clips 78 c with respect to oneanother until clips 78 c are disposed as shown in FIG. 14, whereuponclips 78 c may engage one another as described above.

As shown in FIGS. 30a-c, foundation halves 44, 46 may include recesses82 formed in exterior surfaces 52 of foundation halves 44, 46 aroundclip apertures 80. Recesses 82 may include a plurality of segmentfingers 84 which are pretensioned to deform and frictionally retainclips 78 a-c upon insertion of clips 78 a-c into clip apertures 80.Heads 86 a-c of clips 78 a-c are received within recesses 82 such thatthe top surfaces of heads 86 a-c are substantially flush with externalsurface 52 of foundation 42, thereby allowing upholstery cover 50 touniformly cover and span both foundation 42 and heads 86 a-c of clips 78a-c, such that clips 78 a-c are hidden from view in the assembled sunvisor, and upholstery cover 50 does not need to stretch around clips 78.

As shown in connection with clips 78 b in FIGS. 9-11, each of clips 78a-c may additionally include outwardly directed, external hooks 112which engage the interior surface of foundation 42 to secure clips 78within clip apertures 80 of foundation 42.

Referring to FIGS. 12, 13, 17, and 18, clips 78 a-c may additionally beused with frame members 110 a, 110 b, which are disposed betweenfoundation halves 44, 46. Frame members 110 a, 110 b may be made of aplastic material such as polypropylene, ABS plastic, or nylon, and mayinclude rounded bead portion 114 forming beaded edge 116 of the sunvisor, as shown in FIGS. 13 and 18. As shown in FIGS. 12 and 13, framemember 110 a includes a plurality of openings 118 therein, which mayreceive legs 88 a-c of any of clips 78 a-c therethrough, such as legs 88b of clips 78 b shown in FIGS. 12 and 13, for example, with legs 88 a-cof clips 78 a-c engaging one another as described above to securefoundation halves 44, 46 to opposite sides of frame member 110 a.

As shown in FIGS. 17 and 18, frame member 110 b includes a plurality ofconnecting elements, shown as clip receptacles 120, for example, whichare disposed in an offset, alternating fashion in opposite sides offrame member 110 b. Clip receptacles 120 may be shaped to lockinglyreceive any of clips 78 a-c therein, such as clips 78 c shown in FIGS.17 and 18 for example, to secure foundation halves 44, 46 to oppositesides of frame member 110 b. In this manner, foundation halves 44, 46are not secured to one another by corresponding clips 78 a-c; rather,clips 78 a-c associated with each foundation half 44, 46 engage clipreceptacles 120 provided in frame member 110 b to secure foundationhalves 44, 46 to opposite sides of frame member 110.

Sun visor assembly 74 d, shown in FIGS. 19-21, is similar to sun visorassemblies 74 a-c. However, rather than including a plurality of clips78 a-c associated with each foundation half 44, 46, sun visor assembly78 d includes first connecting strips 122 a, 122 b associated withrespective foundation halves 44, 46. Each connecting strip 122 a, 122 bincludes stem portion 124 having a plurality of integrally formed clips78 d which project therefrom at spaced intervals. Clips 78 d ofconnecting strips 122 a, 122 b may be substantially identical to any ofclips 78 a-c which are described above. Connecting strips 122 a, 122 bmay additionally include bulbous portions 56 which, when pressedtogether as shown in FIG. 21, form rounded bead member 58 which definesbeaded edge 116 around the periphery of the sun visor. Cutouts 76 may beformed in foundation 42 to accommodate protrusions (not shown) of hingeblock 79 to mount hinge block 79 within visor assembly 74 d.Additionally, a clip assembly or vanity mirror assembly may be mountedwithin visor assembly 74 d in a similar manner. Such vanity mirrorassemblies, clip assemblies, and hinge blocks may be similar to thosedisclosed in U.S. Pat. No. 5,580,118, assigned to the assignee of thepresent application, the disclosure of which is hereby incorporated byreference.

As may be understood from the above description of clips 78 a-c, clips78 d of corresponding connecting strips 122 a, 122 b are disposed at 90°with respect to one another to facilitate engagement betweencorresponding clips 78 d, as described above in connection with clips 78a-c. Connecting strips 122 a, 122 b additionally include cutout slots126 which allow rounded flat portion 128 of sun visor assembly 74 to bebent along crease lines 130. Foundation halves 44, 46 may include aplurality of apertures 80 along the peripheral edges thereof, whichreceive clips 78 d of connecting strips 122 a. 122 b therethrough toconnect connecting strips 122 with foundation halves 44, 46. Optionally,each clip 78 d of connecting strips 122 may further include externalhooks 112, as described above, which engage interior surfaces offoundation halves 44, 46 in order to secure connecting strips 122 a, 122b to foundation halves 44, 46. Advantageously, connecting strips 122 a,122 b, having a plurality of clips 78 d integrally formed therewith,allow foundation halves 44, 46 of sun visor assembly 74 d to be cliplocked together without the use of a plurality of individual clips 78a-c, thereby reducing the number of components of sun visor assembly 74d and simplifying the complexity and cost of assembly thereof.

Sun visor assembly 74 e is shown in FIGS. 31a-33, which is similar tosun visor assembly 74 d shown in FIGS. 19-21, and includes secondconnecting strips 170 a, 170 b, each having stem portion 172 with aplurality of integral ratchet legs 174 formed therewith. Ratchet legs174 each include a plurality of catches 176 formed therewith. As shownin FIG. 32, stem portions 172 further include hooks 178 and ribs 179formed therein on opposite sides of ratchet legs 174. When ratchet legs174 are inserted through apertures 80 in foundation halves 44, 46 asshown in FIG. 33, hooks 178 engage the interior surfaces of foundationhalves 44, 46, and ribs 179 abut the interior of apertures 80, such thathooks 178 and ribs 179 cooperate to secure second connecting strips 170a, 170 b to foundation halves 44, 46, respectively.

As shown in FIGS. 31a and 31 b, when foundation halves 44, 46 of visorassembly 74 e are pressed together, catches 176 of opposing ratchet legs174 engage one another in a ratcheting, stepwise manner, with eachratchet leg 174 of one connecting strip 170 a, 170 b extending through acorresponding opening 177 in the stem portion 172 of an oppositeconnecting strip 170 a, 170 b. Referring to FIG. 33, it may be seen thatthe distal ends of ratchet legs 174 do not extend past stem portions 172in the opposite connecting strips 170 a, 170 b, such that upholsterycover 50 may smoothly and uniformly cover connecting strips 170 a, 170b.

Advantageously, the ratcheting, stepwise engagement between ratchet legs174 of connecting strips 170 a, 170 b allows connecting strips 170 a,170 b to be used with foundations 42 of different thicknesses such that,for example, when a relatively thick foundation is used, one or twocatches 176 of corresponding connecting strips 170 a, 170 b may engageone another, and when a relatively thinner foundation is used, two orthree catches 176 of corresponding connecting strips 170 a, 170 b mayengage one another. Connecting strips 170, 170 b each may includebulbous portions 56 which, when pressed together as shown in FIG. 33,form rounded bead member 58 which defines a beaded edge around theperiphery of the sun visor.

Sun visor assembly 74 f is shown in FIGS. 34a-35, including thirdconnecting strips 180 a, 180 b. Connecting strips 180 a, 180 b aresimilar to connecting strips 170 a, 170 b, and such similar featuresthereof will not be further discussed herein. As shown in FIG. 34,connecting strip 180 a includes locking fingers 184, which lockinglyreceive and retain heads 190 of posts 188 formed with connecting strip180 b to secure connecting strips 180 a, 180 b to one another.Connecting strips 180 a, 180 b additionally include catch hooks 192,which retain edge portion 70 of upholstery cover 50 when wrapped aroundthe edge of connecting strips 180 a, 180 b, as well as tapering trailingedges 194, which provide a smooth transition for upholstery cover 50from connecting strips 180 a, 180 b to foundation halves 44, 46,respectively. Catch hooks 192 and trailing edges 194 may be includedwith connecting strips 122 a-b and 170 a-b.

In addition to the above-described embodiments in which foundationhalves 44, 46 may be secured to one another or to frame members 110 a,110 b using connecting elements such as clips 78 a-c or connectingstrips 122 a-b, 170 a-b, or 180 a-b, foundation halves 44, 46 may alsobe secured to a frame member using interlocking systems, which aredescribed below, and which include connecting elements formed in each ofthe foundation halves and frame members.

As shown in FIG. 23, sun visor assembly 74 g includes foundation halves44, 46 which are formed with bent edge portions 132 and connectingelements, the connecting elements shown in FIG. 23 as tabs 134. Withreference to FIGS. 22a-c, in forming bent edge portions 132 and tabs134, outlines 136 of tabs 134 are first die cut in foundation halves 44,46, and a plurality of recessed notches 138 are pressed into foundationhalves 44, 46 within outlines 136. Then, the portions of foundationhalves 44, 46 within outlines 136 are bent to form tabs 134 which dependfrom foundation halves 44, 46 as shown in FIG. 22c. Additionally, edges48 of foundation halves 44, 46 adjacent tabs 134 may also be bent asshown in FIG. 22c to form bent edge portions 132 of foundation halves44, 46.

As shown in FIG. 23, frame member 110 c includes connecting elements,shown as a plurality of offset, alternating slots 140 formed therein,including locking tabs 142 disposed within each slot 140, as shown inFIGS. 24a and 24 b. Tabs 134 of foundation halves 44, 46 are pressedinto slots 140 such that locking tabs 142 of slots 140 sequentiallyengage recessed notches 138 formed in tabs 134 in a ratcheting, stepwisemanner to secure foundation halves 44, 46 to frame member 110 c. Framemember 110 c may additionally include rounded bead member 58 projectingtherefrom, against which bent edge portions 132 of foundation halves 44,46 abut when foundation halves 44, 46 are secured to frame member 110 c.As shown in FIG. 23, upholstery cover 50 is sandwiched between bent edgeportions 132 of foundation halves 44, 46 and rounded bead member 58 offrame member 110 c to secure upholstery cover 50 to foundation 42, withrounded bead member 58 of frame member 110 c extending externally ofupholstery cover 50 to define a beaded edge of the sun visor.

Referring to FIGS. 25-27, sun visor assembly 74 h includes foundationhalves 44, 46 having connecting elements, the connecting elements shownas recessed cavities 144 formed within foundation halves 44, 46.Recessed cavities 144 include insertion openings 146 and slots 148, withslots 148 having wide portions 150 and narrow portions 152.Additionally, foundation halves 44, 46 may include bent edge portions132 adjacent recessed cavities 144. Frame member 110 d is disposedbetween foundation halves 44, 46 and includes connecting elements shownas a plurality of offset, alternating T-shaped tabs 154 projecting fromopposite sides of frame member 110 d.

To secure foundation halves 44, 46 to frame member 110 d, heads 156 ofT-shaped tabs 154 are received within insertion openings 146 and wideportions 150 of slots 148, whereupon frame member 110 d and foundationhalves 44, 46 are moved laterally with respect to one another such thatstems 158 of T-shaped tabs 154 pass into narrow portions 152 of slots148 to secure foundation halves 44, 46 to frame member 110, as may beseen from FIGS. 25-26b. Optionally, recessed cavities 144 may be shapedto be deeper in the area around wide portions 150 of slots 148, andrelatively shallower around narrow portions 152 of slots 148, such thatheads 146 of T-shaped tabs 154 frictionally engage slots 148 to agreater extent around narrow portions 152 of slots 148 than widerportions 150 of slots 148 to provide a greater friction fit betweenT-shaped tabs 154 and recessed cavities 144. As shown in FIG. 27, heads156 of T-shaped tabs 154 are substantially flush with exterior surfaces52 of foundation halves 44, 46, thereby allowing upholstery cover 50 touniformly cover and span both foundation halves 44, 46 and T-shaped tabs154, such that T-shaped tabs 154 are hidden from view in the assembledsun visor, and upholstery cover 50 does not need to stretch aroundT-shaped tabs 154.

Additionally, frame member 110 d may include rounded bead portion 114,against which bent edge portions 132 of foundation halves 44, 46 abut onopposite sides of rounded bead portion 114, with upholstery cover 50sandwiched between bent edge portions 132 of foundation halves 44, 46and rounded bead portion 114 of frame member 110 d to secure upholsterycover 50 to foundation 42. Rounded bead portion 114 of frame member 110is disposed externally of foundation halves 44, 46 and upholstery cover50, and forms an outer edge of the sun visor.

Sun visor assembly 74 i is shown in FIG. 28, in which foundation halves44, 46 are secured to one another using adhesive strips 162. Adhesivestrips 162 include adhesive pad 164 having an exposed adhesive onopposite sides thereof, such that, as shown in FIG. 28, when adhesivestrips 162 are sandwiched between foundation halves 44, 46, adhesivestrips 162 secure foundation halves 44, 46 to one another, with edgeportions 70 of upholstery cover 50 wrapped around the edges offoundation halves 44, 46 and tucked between foundation halves 44, 46 tosecure upholstery cover 50 to foundation 42. Alternatively, adhesivestrips 162 may be strips of a double-sided adhesive tape. Suitableadhesive strips and double-sided adhesive tapes include, for example,VHB™ Double Coated Foam Tapes and Adhesive Transfer Tapes, availablefrom 3M Company of St. Paul Minn. (VHB™ is a trademark of 3M Company).However, other suitable adhesive strips and double-sided adhesive tapesare readily available.

As shown in FIG. 28, a plurality of adhesive strips 162 may be spaced atintervals between foundation halves 44, 46 to secure foundation halves44, 46 to one another. Optionally, adhesive strips 162 may be cut intovarious shapes to correspond to the contours of the edges of foundationhalves 44, 46, and/or to ensure maximum contact between foundationhalves 44, 46 and adhesive strips 162.

As shown in FIG. 9, frame member 110 e is disposed between foundationhalves 44, 46, and may include a plurality of adhesive strip mounts 166to which adhesive strips 162 are adhered. Adhesive strip mounts 166 maybe integrally formed with frame member 110 c, and may be curved as shownin FIG. 29 to correspond with bent edge portions 132 of foundationhalves 44, 46. Upholstery cover 50 may be wrapped around the edges offoundation halves 44, 46 and tucked into the interior of sun visor 74between foundation halves 44, 46 and frame member 110 e to secureupholstery cover 50 to foundation 42. Further, adhesive strips 162 maybe adhered both to edges 70 of upholstery cover 50 and to bent edgeportions 132 of foundation halves 44, 46 to further secure upholsterycover 50, foundation halves 44, 46 and frame member 110 e together.

As shown in FIGS. 8, 11, 13, 16, 18, 21, 23, 25, 27-29, 33, and 35, edgeportions 70 of upholstery cover 50 are wrapped around the edges offoundation halves 44, 46, and are sandwiched between foundation halves44, 46 or alternatively, between foundation halves 44, 46 and framemembers 110 a-e. Edge portions 70 of upholstery cover 50 may be securedto foundation halves 44, 46 using an adhesive, however, the interlockingengagement between foundation halves 44, 46 or between foundation halves44, 46 and frame members 110 a-e may be effected with sufficient forceto sandwich edge portions 70 of upholstery cover 50 between foundationhalves 44, 46 or between foundation halves 44, 46 and frame members 110such that upholstery cover 50 is secured to foundation 42 without theuse of an adhesive.

While this invention has been described as having a preferred design,the present invention can be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains and which fallwithin the limits of the appended claims.

What is claimed is:
 1. A sun visor, comprising: a substantially flatfoundation having two foundation halves, the foundation halves havingcorresponding shapes that define an edge of the sun visor; a coverdisposed over the foundation and forming an exterior surface of the sunvisor; a frame member disposed intermediate the foundation halves; atleast one first connecting element associated with each of thefoundation halves; and at least two second connecting elementsassociated with the frame member, the first connecting elementsrespectively engaging the second connecting elements to secure thefoundation halves to the frame member.
 2. The sun visor of claim 1,wherein the first connecting elements comprise clips, and the secondconnecting elements comprise clip receptacles integrally formed with theframe member.
 3. The sun visor of claim 1, wherein the first connectingelements comprise tabs depending from said foundation halves, and saidsecond connecting elements comprise slots within the frame member intowhich the tabs are received.
 4. The sun visor of claim 3, wherein theframe member includes a rounded bead member disposed along the edge ofthe sun visor externally of the foundation and the cover.
 5. The sunvisor of claim 4, wherein the foundation halves include edges curvedinwardly toward opposite sides of the bead member, the cover disposedaround the curved edges and sandwiched between the foundation halves andthe frame member.
 6. The sun visor of claim 3, wherein the foundationhalves are secured to opposite sides of the frame member, the slotsalternatingly disposed in the opposite sides of the frame member.
 7. Thesun visor of claim 3, wherein the tabs each include a plurality ofnotches and the slots include hooks, the hooks each engaging one of thenotches upon insertion of the tabs into the slots to lock the foundationhalves to the frame member.
 8. The sun visor of claim 1, wherein thefirst connecting elements comprise recessed cavities which depend fromthe foundation and include slots, and the second connecting elementscomprise tabs which project from the frame member and are receivedwithin the slots.
 9. The sun visor of claim 8, wherein the tabs arealternatingly disposed in the opposite sides of the frame member. 10.The sun visor of claim 8, wherein each tab includes a stem portiondepending from the frame member and terminating in a head, and the slotsinclude a larger portion receiving the heads therethrough and a smallerportion slidably receiving the stem portion to secure the foundationhalves to the frame member.
 11. The sun visor of claim 8, wherein theframe member includes a rounded bead member disposed along the edge ofthe sun visor externally of the foundation and the cover.
 12. The sunvisor of claim 11, wherein the foundation halves include edges curvedinwardly toward opposite sides of the bead member, the cover disposedaround the curved edges and sandwiched between the foundation halves andthe frame member.
 13. The sun visor of claim 1, wherein the frame memberincludes a rounded bead member disposed along the edge of the sun visorexternally of the foundation and the cover.